Week 7: Molding & Casting

About 📓

  • Group assignment: Review the safety data sheets for each of your molding and casting materials. Compare test casts with each of them compare mold making processes

  • Individual assignment: Design a mold around the process you'll be using, Produce it with a smooth surface finish that it does not show the production process toolpath. Use it to cast parts

  • Cactus Molding Process ✏️

    For this project I decided I needed more succulents around my house. so I thought it was a great opportunity to create a mold of a cactus. At first I wanted to create a mold from a model however I thought this strategy would be more effective in being able to produce more at a faster speed. so I created the cactus and split it in half.

    I used XTC-3D as a protective coating for smoothing and finishing 3D printed parts that does not melt plastic. XTC‑3D™ fills in 3D print striations and creates a smooth, high gloss finish. The need to post finish is almost eliminated. XTC‑3D™ can be applied to both SLA and SLS prints. It works with PLA, ABS, Laywoo, Powder Printed Parts and other rigid media such as EPS, EPDM and urethane foam as well as wood, plaster, fabric, cardboard and paper.

    Once that cured for 4 hours, I used Oomoo 25 to fill the mold. It was surprising to see how vicious the Oomoo was as it went into the mold. I originally drilled a hole in the middle to try to keep it through each half but it was too thick. so we let it cure for 9 hours and then I went in over the moon and cut around some of the rough edges. Photo

    Group Assignment

    We made little square cups in Solidworks with drafted walls to test the material properties of all the molding and casting materials. These cubes are roughly 1x1x1 cm with a 10 degree draft angle for easy removal. I made little caps that fit over the bottom of the box to seal the hole. The hole is there so that the mold can be pushed out.

    We then molded little cubes of the following materials: Ecoflex 30, Ecoflex 50, Dragonskin, Sorta-Clear 37, Oomoo 25, and Oomoo 30. Each are mixed in 1:1 ratios of two materials, and have different working and curing times.

    Oomoo 25: No Vacuuming - No Scale - Easy To Use OOMOO™ 25 is an easy to use tin cure silicone rubber compound that features a convenient one-to-one by volume mix ratio (no scale necessary). It has a low viscosity for easy mixing and pouring vacuum degassing is not necessary. This product cures at room temperature with negligible shrinkage. OOMOO ™ 25 has a 15-minute pot life and 75-minute cure time.

    Oomoo 30: An easy to use tin cure silicone rubber compound that features a convenient one-to-one by volume mix ratio (no scale necessary). It has low viscosity for easy mixing and pouring vacuum degassing is not necessary. This product cures at room temperature with negligible shrinkage. OOMOO ™ 30 has a 30-minute pot life, with a six-hour cure time.

    Sorta Clear 37: SORTA-Clear™ Series rubbers are premium water clear translucent silicone rubbers (platinum catalyst) which cure at room tempe rature with negligible shrinkage. SORTA-Clear ™ 37 has Shore 37A hardness and features high tensile and tear strength. This product also offers the convenience of a 1A:1B by volume mix

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    Reflection 🤔

    I was very intimidated by the molding and casting process at first. However, after getting into the casting room at The Reef I learned that this process was actually very simple and intuitive.

    I'm happy that I started this project over the weekend to 3D print and experiment because the one primary takeaway is just how much time the process takes. I initially wanted to try to create a mold out of a sheer 3D print which was my German Shepherd however instead I just printed the direct mold of my cactus in half with infusion and I thought this was ineffective way to quickly mold I think moving forward I would have 3D printed a row of cacti so I could cast in bulk.

    Overall I'm really excited by this project and how simple it was. I definitely will be using this process moving forward for a variety of projects!

    Jessica & I had a lot of fun learning this week!

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    Project Resources 🔗

    Cactus.stl